Footwear and method of making the same



Feb. 21, 1939. A. F.- DONOVAN I 2,147,337

FOOTWEAR AND METHOD OF MAKING THE SAME Filed 0012'. 27, 1936 Ajred 121902600072,

e9 piece. relative to.

Patented Feb. 21, 1939 UNITED STATES. PATENT OFFICE.

' 2,147,887 FOOTWEAR METHOD OF MAKING THE Alfred F. Donovan, Boston,

Mass... assignor to E. T. Wright 8: Company, Inc., Rockland, Man.

a corporation of Massachusetts Application October 27, 1936, Serial No.

11 Claims. ('01. 12-146) This invention pertains to footwear and relates more particularly to an improved bottom structure for shoes and the fined the bottom structure completed shoe.

' at: insole proper-or to each othergandfin consequence; certain or the advantages which should always be in actual;

necessarily show that the parts oi positioned. thewearen although expecting to receive L the benefits-.01.,

' he Brown improvements.

aoniay-be deprivedlof'such benefits and may even shoe parts are sumciently 1 suitor ill'eiiectsit the out of place. As above noted, the principal ob iectof the present invention is to provide an improved bottom construction suchas] substantialiirmly attached tothe other elements of the shoe bottom.

50 A further object is method of procedure to providean improved in assembling the constituent elements of the bottom structure 01' a shoe so as to insure accuracy of relative position of such constituent parts.

Other objects and advantages of the invention like. .As herein dehe patents b mes m 1.249.315 an: the utilityfoi a stiii and strong. shank piece and associated metatarsal pad has been I tainable. in following the teachings of j said Brown patents are practice sometimes partially orcomfp etely-losh- "'Sinceinspection of the completed I constituent elements of will be pointed out in the following more detailed description and by reference to the accompanying drawing wherein Fig. 1 is a plan view of the insole member of the shoe bottom; i Fig. 2 is a bottom view of aninsole member provided with a sewing Fig. 3 is a section to larger scale substantially in on the line 33 of Fig. 2;

Fig. 4, is a perspective view-oi a metatarsal pad, of preferred shape, designed to form one oi the constituent elements of the improved bottom structure; J Fig. 4a is a bottom View of the insole member 'owingthe metatarsal pad associated theref I Fig. 5 is a transverse section to larger see.

Fig. 7 is a section to larger scale on the line Fig. 8 is a bottomview of the insole oi Fig. 6 showing it as having beenv provided with a transverse shank positioning recess extending crosswise of the metatarsal pad;

Fig. 9 is a fragmentary longitudinal section on v the line 9-4 of Fig. 8; a

Fig. 10 is a bottom view of an piece orstiflener design'edto form one 01 the the shoe bottom structure;

Fig. 11 is a plan view of the shank piece of Fig. 10;

, Fig. 12 is a bottom view or the insole 01 Fig. 8

with the shank piece assembled therewith;

Fig. 13 is a iragmentarylongitudinal section. to larger scale, substantially on the line ill3 oi Fig. 12; and

Fig. 14 is a fragmentary longitudinal section, to larger scale, substantially on the line il-il of Fig. 12.

transverse slashes forepart, designed to furnish means for manipulating or supporting the metatarsal arch of the foot of the wearer of the shoe. as described in the patent to Brown No. 1,656,556 above referredto. The insole I is also shaped at its shank portion to provide angularly disposed lateral portions 3 and 4 meeting at the longitudinal furrow or depression I, the part 2 constituting the normally substantially horizontal support for the outer portion of the foot while the part 4 slopes upwardlrand is designed to prevent or to some extent to remedy tendency of the foot to pronate, all as more fully described in the aforesaid patents to Brown. This shaping of the insole member .I may be accomplished in a press and by means of dies of suitable design. The heel end of the insole I may be substantially flat to form the heel seat of the shoe, its junction with the shank portion being defined if desired by a line 1, consisting, for example, of spaced dots or depressions adapted to facilitate subsequent operations, although this line of demarcation is not necessary nor an essential feature of the present invention.

Referring to Fig. 2 the bottom side of this insole member I, throughout such portion of its forepart I as is desired, may be furnished with 9 or other suitable means for making the forepart flexible, and when the bottom structure is to form part of a welt shoe, the under side of the insole will be provided with a sewing rib III. This sewing rib may conveniently be formed by channeling operations, leaving the sewing channel ll (Fig. 3) at the inner side of the rib and the marginal lip l2 at its outer side This sewing rib may, however, be formed in any desired manner known to those skilled in the art.

'Ihe'insole, in so far as the above description is conoerned,'i's substantially like that disclosed in the Brown patents referred to, but in the present instance, in forming the upper side of the insole (such elevation being produced as above described by a die pressing operation) .the under side of the insole is furnished with pad positioning elements designed to assist the operator in placing the metatarsal pad accurately at the proper position relatively to some fixed part of the insole. In forming the elevation 2, a corresponding recess l3, Fig. 2, is made at the under side of the insole. Preferably this reoess is of more or less segmental contour, having the substantially straight side edges M and II and the curved forward edge it, the recess being deeperv at its rear end or apex,- that is where the straight edges I4 and I! meet, than at its forward edge. Preferably, coincidentally with the formation of the recess l3, there are provided three or more pad positioning elements, for example small depressions or pits 20, 2| and 22 in the material of the insole. These pits may conveniently be formed by means of pinlike projections upon the die which forms the recess l2. One of these pits 20 is'preferably at the junction of the straight edges I4 and I! of the depression with a longitudinal ridge H on the bottom surface of the insole, said ridge correspending with the depression or furrow which forms the line of demarcation between the angularly disposed surfaces 3 and l. The other padlocating pits 2i and 22 are preferably disposed'ad- Jacent to the left and right-hand corners, respectively, of the recess l2. While three such padlocating elements are here illustrated, it is contemplated that a greater number may be provided if desired. As above described these pits 20,

elevation 2 at the 2| and 22 are preferably formed coincidentally with the formation of the recess i3 and by means of the same dies. In forming the recess IS, the die press which is employed is provided with gauges for contact with the heel end of the insole and with its lateral margins, so that the recess is accurately located mechanically and may always be depended upon to occupy the proper position laterally and longitudinally of the insole. Thus, likewise, the pad-positioning elements 20, 2i and 22 will be accurately located both laterally and longitudinally.

In accordance with the present invention a metatarsal pad 23 (Fig. 4) is provided, being designedto fill the recess l3 so as to provide for a substantially level under surface at this point, although the material of the insole itself protrudes upwardly at this point. For this purpose, the pad 23, which may be made of any suitable material such as leather, leatherboard, rubber, sheet cork or the like, is shaped to a generally segmental contour and size similar to that of the recess i3, having the straight edges 24 and 25 and the curved edge 26, the apex or point where the edges 24 and 25 meet being substantially thicker than the curved edge so that the pad may be likened to a segmental wedge.

Having provided the recess i3 with its pad-positioning elements and having provided the pad as just described, the operator coats the wall of the recess IS with adhesive and likewise coats one side of the pad 23 with adhesive, if desired, and then positions the pad in the recess so that the apex 21 of the pad is located at the point 20 and its edges 24 and 25 substantially contact the location elements 2| and 22. The adhesive is then allowed to set, thus fixing the pad to the insole proper, and by reason of the procedure above outlined the proper location of the pad is accurately assured.

In accordance with'one desirable procedure, although not absolutely necessary to the practice of the present invention, the insole member, forwardly of a transverse line It which defines the rear end of the sewing rib, comprises a layer of reinforcing material 28. This reinforcing material may be cloth or any other suitable substance designed to impart toughness to the inner sole and particularly to strengthen the sewing rib so as to insure properretention of the stitches by which the welt is secured to the latter. This reinforcing layer 28 is usually adhesively united to the insole proper, and extends across and substantially conceals the pad 22, the portion 23 of this reinforce material which overlies the pad being substantially fiush with that portion of the underside of the insole forwardly of the pad.

After this reinforce layer has been applied (if it is used) a transverse shank-positioning recess or slot 29 is formed at a predetermined distance from one end of the insole, preferably from the heel end 32. This transverse recess, which in dents both the covering or reinforcing material 28 and the pad 23 itself, is preferably made by the use of a suitable die, in a die press mechanism or the like having gauges which contact with the heel end of the insole and with the lateral edges of the latter, the die having a positioning element designed to be disposed longitudinally of the ridge II. By the use of such a die and die press the transverse recess or slot 29 is accurately formed at a predetermined distance from the end 30 of the insole and makes a definite and predetermined angle, for example. substantially 90 with the longitudinally extending ridge l1. Preferably this recess 29 is furnished at spaced points with a pair of elongate sockets 3| and 32, respectively, ac-

curately positioned laterally of the, insole and which in effect form deepened portions of the recess or slot,-extending well into the pad 23 but 5 preferably not entirely through the latter.

'In accordance with the present invention an improved shank piece or stiifener member 33 is provided (Figs. and 11). This stiffener comprises the angularly disposed portions 35 and 36, m respectively. which are adapted, in the completed shoe, to underlie the parts I and 4, respectively, of the insole proper, the included anglebetween the parts 35 and 36 receiving the ridge ll of the insole. These portions 35 .and 3B of the shank 15 piece meet at a longitudinally extending stiffen- "ing rib 31, the shank piece preferably being made from sheet steel or other stifi material, as for example by a die press operation. The shank piece is preferably furnished with. a narrow tail portion 34 and with a wider head portion 38,

here shown as of substantially triangular contour and which is adapted to contact with the triangular rear portion 23 (Fig. 8) of the pad 23, that is to say, that portion of the pad 2|} which lies rearwardly of the recess or slot 29. The forwardend of the shank piece is furnished with an upturned flange 39 (Fig. 11) which is designed to seat in the transverse recess or slot 2! of the pad 23, and is also preferably furnished I0, with prongs 40 designed to enter the sockets ii and 32, respectively, in the pad. 3 These prongs 1 may be of such length that when driven-into the substance of the pad they will provide for anchorage of the shank piece to the pad, 91-

I though ordinarily these prongs merely constitute positioning elements and have little actual attaching function.

For securing the forward end ofthe shank piece to the other elements of thebottom struclfl ture it is preferred to provide the'shank piece ,with a patch ll of some flexible material such, for example, as leather, textile fabric, rubber or the like. This patch is conveniently secured to the shank piece by means of rivets I! or the like.

as although it is contemplated that it may be secured to the shank piece by means of a powerful adhesive, such, for example, as one of the synthetic resins or rubber compounds. This patch ll extends forwardly beyond the forward end of the so shank piece proper and is designed to overlie the surface 23- at the forward portion of the pad.

In assembling the shank piece with the other parts of the bottom structure it is only necessary for the operator to place the flange 38 in the i5 recess 2!, disposing the prongs 40 in the .slots 3i and II, and then to swing therear endof the shank piece slightly in a transverse direction so as to center it properly with reference to-those parts of the sewing rib between which itis dis- 00 posed. For example, the shank piece may be so positioned. as shown in Fig. 12, that one of its edges engages the inner surface of the sewing rib. Since the recess or slot 29, with its sockets II and 32, has been-accurately and mechanically 86 fixed at a definite predetermined distance from the heel end of the insolerand since the flange I! is accurately related to the convergent rear edges of the triangular portion 38 of the shank piece, it is clear that the mere positioning of 10 the flange as in the recess-29 will with certainty position the shank piece properly .in relation to the metatarsal pad. The operator thus has little discretion in his location of the shank piece, and since both pad and shank piece are thus posifg tinned with certain knowledge that they occupy a "middle heel". This'recess the proper relationship to the other it may be assumed that, with, ordinary supervision, substantially perfect shoes may be made in accordance with the present method and by the use of the structural elements above described in so farv 5 as the location of the metatarsal pad and the shank piece is concerned. After the shank piece has thus been positioned, it may, be permanently united to the other parts byadhesively securing the patch 4| to the relnforcamember 2| -(or 10 directly to the under of the inner sole if the reinforce is not used) while theirear-part of the shank piece may be permanently secured to the rear end of the innersole by means of tacks or other suitable fastenersfpasslng tin-ouch onen- 15 lugs 43 provided in the tall portion 34 of. the shank piece. As illustrated, the openings '43 are so arranged that a line joining them would extend diagonally with reference to the the lengthv of theshank piece, this arrangement preventing undue weakening of the shank piece such as might occur if these openings werealigned trans versely. As pointed out in, the above-notcd patents to Brown, this shank piece is designed to be very still and in effect to extend the supporting action of the heel of theshoe forwardly toward the ball of the shoe. When called upon to act in this manner the'shank piece is subjected to a powerful bending stress, and whenthe openings 43 are aligned "transversely, it sometimes so happens that the shank piece breaks at this point,

whereas by arranging the openings as here illustrated there is less possibflity of breakage.

It is further to be noted in this connection that the forward end cf-the shankpicce, as defined by the flange, is disposed. at the transverse recess or channel 28 and that-thisrecess constitutes a what may be termed a line-of weakness just at the Junction of the shank and ball portions of the bottom structure, such line of weakness clearly defining the forward end of the very stiff and rigid portion of the bottom structure, and setting it on from the relatively very flexible A forepart. Thus this'recess 28 defines the forward limit of a still cantilever-like forward extension 5 of the shoe heel proper which, with respect to its foot supporting function, may be likened to lathu performs two functions, to wit the accurate location of the forward end of the shank piece relatively to 5 the metatarsal pad and to form a clear line of; demarcation between'the stiff rear portion of the shoe bottom structure and the flexible forward portion thereof.

While I have hereinabove described certain,

desirable embodiments of the inventiomby way; of example, as well as a preferred method of practicing the invention, I wish it to be understood that the invention is not necessarily limited to the precise details hereinabove outlined but is to be regarded as of a scope such as set forth and delineated in the accompanying claims.

I claim:

1. A shoe bottom structure comprising an insole member, a shank piece, and a metatarsal pad having intersecting edges, the insole member having therein a pad-receiving recess, the insole having a plurallty of spaced pad-positioning elements disposed inwardly of its margin and adjacent to the edges of the recess, said elements defining intersecting lines and being operative to assist an operator in properly disposing a pad within the recess.

a recess for the the margin of the recess.

3. A shoe bottom structure comprising an insole member having therein a recess for the reception of a metatarsal pad, and a plurality of spaced integral pad-positioning elements moulded in the substance of the insole proper adjacent to the margin of the recess.

4. A shoe bottom structure comprising an insole having a recess in its under surface for the reception of a metatarsal pad, said recess being of generally segmental contour with its apex directed rearwardiy, the insole having a longitudinal ridge running rearwardly from the apex of the recess toward the heel, the material of the insole being shaped to provide pad-positioning elements, one adjacent to the apex of the recess and one at least adjacent to each lateral corner of the recess for assisting the operator in positioning a pad in the recess,

5. A shoe bottom structure comprising an insole, a metatarsal pad and a shank piece, the pad having therein a transverse slot disposed at an accurate distance from one end of the insole defining the proper location of the forward end of the shank piece, said recess having a pair of spaced elongate deepened portions, and the shank piece having a flange at its forward end which fits within said slot, and a pair of prongs which fit into said slot-like deeper portions of the slot.

6. A shoe bottom structure comprising an insole having in its under surface a moulded-in recess of substantially segmental contour for the reception of a metatarsal pad, pad-positioning elements adjacent-to the margin of the recess, a

pad in said recess, means fixing the pad within the recess, the insole comprising a layer of reinforce material substantially coextensive with its bottom surface forwardly of the heel and covering the pad, there being a transverse slot extending upwardly into said reinforce material and pad, said slot being at an accurate distance from the rear having in its bottom surface a moulded-in recess for the reception of a metatarsal pad, pad-positioning means adjacent to the margin of the recess, and a longitudinally extending ridge for the reception of the angle of a transversely angular shank piece, and a pad fixed inthe recess, the insole comprising a layer of reinforce material substantially coextensive with its bottom surface forwardly of the heel and concealing the pad, there being a transverse slot extending into the reinforce material and pad at an accurate distance from the heel end of'the insole, and a shank stiil'ener of transversely angular cross section having a positioning flange at its forward end disposed in said transverse slot and receiving the longitudinally extending rib of the insole in the included angle between its lateral portions. I

8. Method of making a bottom structure for a shoe which comprises as steps, providing an insole with pad-locating means, assembling a meta- :stlfi'ener with the insole so that its positioning element is disposed in the slot in the pad, and permanently uniting the stiffener to the insole.

9. Method of making a bottom structure for a shoe which comprises as steps providing an insole having a reinforce layer at its under side, forming a transverse slot in said reinforce layer located at a definite and accurately predetermined distance from one end of the insole, providing a shank stiffener having a positioning element adjacent to its forward end, assembling the shank stiffener with the insole so that its positioning element is disposed in the slot in the reinforce layer of the insole, and permanently uniting the shank stiffener to the insole.

10. A shoe bottom structure comprising an insole, a metatarsal pad and a shank piece, a layer of reinforce material underlying the pad and overlying the forward portion at least of the Y shank piece, there being a transverse recess in the reinforce layer and the pad, said recess being disposed at an accurate distance from one end of the insole and defining the proper location for the forward end of the shank piece, said recess having a pair of spaced elongate deepened portions and the shank piece having an upturned flange at its forward end which engages the recess, and a'pair of prongs which extend upwardly into the respective deepened portionsv of the recess.

11. Method of making a bottom structure for a shoe which comprises as steps providing an insole and a metatarsal pad, applying the pad to the under side of the insole, applying a reinforce layer to the under side of the insole so as to cover the pad, forming a transverse-recess in the reinforce layer and the pad at a definitely and accurately predetermined distance from one end of the insole, providing a shank stiffener having a positioning element adjacent to its forward end, assembling the shank stiffener with the insole so that its positioning element is disposed in said recess, and permanently uniting the shank stiffener to the insole.

ALFRED F. DONOVAN. 

